Baking system for a gas cooking appliance

ABSTRACT

A gas cooking appliance including a gas oven cavity for baking a food item, the gas oven cavity including a top surface and a bottom surface, a first heat source disposed adjacent the bottom surface of the gas oven cavity, a second heat source disposed adjacent the top surface of the gas oven cavity, and a controller configured to cycle the first heat source and the second heat source for providing heat above and below the food item during baking

BACKGROUND OF THE INVENTION

The present disclosure relates generally to cooking appliances, and in particular to controlling a bake cooking cycle in a gas oven cavity of a gas cooking appliance.

Generally, cooking appliances such as gas ranges cycle a single heat source during a bake cooking cycle within an oven cavity of the cooking appliance. This single heat source is generally at a bottom of the oven cavity and beneath the items being baked. The cycling of a single heat source (e.g. turning the heat source on and off) located beneath the items may result in uneven cooking. For example, the bottom of the items may be seared or browned while the top(s) of the items remain substantially free from browning.

It would be advantageous to be able to provide multiple heat sources in a gas oven cavity that addresses the problems identified above.

BRIEF DESCRIPTION OF THE INVENTION

As described herein, the exemplary embodiments overcome one or more of the above or other disadvantages known in the art.

One aspect of the exemplary embodiments relates to a gas cooking appliance. The gas cooking appliance includes a gas oven cavity for baking a food item, the gas oven cavity including a top surface and a bottom surface. The gas cooking appliance also includes a first heat source disposed adjacent the bottom surface of the gas oven cavity, a second heat source disposed adjacent the top surface of the gas oven cavity, and a controller configured to cycle the first heat source and the second heat source for providing heat above and below the food item during baking.

Another aspect of the exemplary embodiments relates to a system for cycling a first heat source and a second heat source during a bake cycle of a gas cooking appliance, the gas cooking appliance having a gas oven cavity and the first heat source and the second heat source are disposed inside the gas oven cavity. The system includes a controller configured to cycle the first heat source and the second heat source for providing heat above and below food items placed within the gas cooking appliance, and the gas oven cavity includes a top surface and a bottom surface, the first heat source being disposed adjacent the bottom surface and the second heat source being disposed adjacent the top surface.

Still another aspect of the disclosed embodiments relates to a method for cycling a first heat source and second heat source of a gas cooking appliance during baking, where the gas cooking appliance includes a controller and a gas oven cavity having a top surface and a bottom surface, the first heat source being disposed adjacent the bottom surface and the second heat source being disposed adjacent the top surface. The method includes activating one of the first heat source and second heat source with the controller, activating another one of the first heat source and second heat source with the controller, and between activation of the one of the first heat source and second heat source and/or the another of the first heat source and second heat source, deactivating both of the first heat source and the second heat source with the controller for a predetermined period of time, wherein at least one of the first heat source and second heat source comprises a gas burner.

These as other aspects and advantages of the exemplary embodiments will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. Moreover, the drawings are not necessarily to scale and, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein. In addition, any suitable size, shape or type of elements or materials could be used.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic illustration of an exemplary gas cooking appliance incorporating aspects of the disclosed embodiments;

FIG. 2 is a schematic illustration of a portion of the appliance of FIG. 1 in accordance with an exemplary embodiment; and

FIG. 3 is an exemplary flow diagram illustrating aspects of the disclosed embodiments.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION

In one exemplary embodiment, referring to FIG. 1 a cooking appliance 100 is provided. The cooking appliance 100 may be any suitable cooking appliance, including but not limited to gas cooking appliances. In the examples described herein, the cooking appliance 100 is configured as a free standing range. However, it should be understood that while the embodiments of the invention are described herein with respect to a free standing range, the aspects of the disclosed embodiments may be applied to any suitable cooking appliance with/without a cooktop and/or oven substantially similar to that described herein.

In one embodiment, the cooking appliance 100 of FIG. 1 is a gas operated cooking appliance having an oven 120. The oven 120 of FIG. 1 includes a gas cavity or gas oven cavity 200 having first and second heat sources. The first and second heat sources are configured to be cycled (e.g. selectively turned on and off) for providing heat both above and below cooking items, such as food, being baked within the gas oven cavity 200.

As illustrated in FIG. 1, the cooking appliance 100 includes a frame or housing 130. Internal cavities are formed within the housing 130, such as the gas oven cavity 200 of the oven 120, and/or drawer/mini-oven 140 for storing/baking items. The cooktop 110 includes one or more cooking grates 105 and respective burners 106 that are controlled in any suitable manner. In one example, each of the burners 106 may be controlled by a respective control knob 150 that is configured to regulate, for example, an amount of fuel provided to the respective burner. The cooking appliance 100 may also include a control unit 170 for controlling the heat sources within the gas oven cavity 200. The control unit 170 may be suitably configured to control baking, broiling, cleaning, or other operations of the oven 120.

Referring to FIG. 2, the gas oven cavity 200 of the oven 120 includes side surfaces 200S, a top surface 200T and a bottom surface 200B. The side surfaces 200S may include one or more sets of protrusions 260 or other suitable support members. The protrusions 260 are configured so that oven racks 231-233 may be placed on the protrusions 260 for supporting items within the gas oven cavity 200 during, for example, a bake cooking cycle or baking A first heat source 210 is disposed within the gas oven cavity 200 adjacent the bottom surface 200B. A second heat source 211 is disposed within the gas oven cavity 200 adjacent the top surface 200T. In one aspect of the exemplary embodiments, the first and second heat sources 210, 211 are gas burners. In other aspects of the exemplary embodiments an electrically powered heat source such as an electric heating element, conventional resistance heaters, ceramic or halogen type radiant heaters, or other suitable electrically powered heat source(s) may be disposed adjacent the top surface 200T in addition to or in lieu of the gas burner 211. In still other aspects of the exemplary embodiments, one or more of the first and the second heat sources may be, for example, an electric heating element or a gas heating element such as radiant gas or ceramic burners.

In this example, the first and second gas burners 210, 211 are of conventional design and obtain fuel from a suitable fuel supply or source 290. In one aspect of the exemplary embodiments, the control unit 170 is configured to control an amount of fuel provided by the fuel source 290 to a respective one of the first and second gas burners 210, 211. For example, the control unit 170 may control one or more valves, solenoids, or other flow control devices 250 for adjusting an amount of fuel provided by the fuel source 290 to each of the first and second heat sources 210, 211. In other examples, the control unit 170 may be configured to control one or more variable resistive devices (in addition to at least one gas burner) where the gas oven cavity 200 includes electrically powered heat source for controlling the output power of the electrically powered heat source.

During baking, the control unit 170 controls the amount of fuel provided to the first and second gas burners 210, 211, to selectively cycle the burners on and off. In this manner, the tops and bottoms of the items being baked (e.g. located on the racks 231) are substantially evenly browned or cooked. For example, during baking the controller 170 cycles the first heat source 210, which is located beneath the items being baked, on for a first predetermined length of time (FIG. 3, Block 300). The first predetermined length of time is generally a length of time needed to achieve and/or maintain a predetermined temperature within the gas oven cavity 200. After expiration of the first predetermined length of time the first heat source 210 is turned off or deactivated for a second predetermined length of time. The second heat source 211 is then activated for a third predetermined length of time for providing heat above the items being baked. The third predetermined length of time is generally sufficient to achieve and/or maintain the predetermined temperature within the gas oven cavity 200. At the expiration of this third predetermined length of time, the second heat source 211 is turned off or deactivated for a fourth predetermined length of time before the cycling of one of the first or second heat sources 210, 211 continues (e.g. is repeated). The second and fourth lengths of time (e.g. the time periods which the first and second heat sources 210, 211 are off) are generally sufficiently long enough to ensure substantially complete combustion of the fuel provided to a respective one of the first and second heat sources 210, 211 and/or to ensure a sufficient fuel supply to both the first and second heat sources 210, 211.

For exemplary purposes only, in one embodiment, the first heat source 210 is a 20,000 BTU/hr heat source and the second heat source 211 is a 14,500 BTU/hr heat source. In alternate embodiments one or more of the first and second heat source may be an infrared heat source. Operation of these heat sources 210, 211 may be controlled differently depending on an operational temperature range or band of the gas oven cavity 200. In one aspect of the exemplary embodiments, operation of the heat sources 210, 211 is divided into two or more temperature ranges for baking For example, a first temperature range corresponds to baking temperatures below about 390 degrees Fahrenheit and a second temperature range corresponds to baking temperatures above about 390 degrees Fahrenheit. The control unit 170 is configured such that the first and second heat sources 210, 211 are activated and deactivated differently for each of the temperature ranges. In one exemplary operation of the first and second heat sources 210, 211 during baking at temperatures below about 390 degrees Fahrenheit, the first heat source 210 is activated for about 45 seconds (e.g. the first predetermined length of time). After about 45 seconds the first heat source 210 is deactivated for about 10 seconds (e.g. the second predetermined length of time). The second heat source 211 is then activated for about 30 seconds (e.g. the third predetermined length of time) for providing heat above the items being baked. After about 30 seconds the second heat source 211 is deactivated for about 15 seconds (e.g. the fourth predetermined length of time) before the cycling of the first and second heat sources 210, 211 is repeated. In another exemplary operation of the first and second heat sources 210, 211 during baking at temperatures above about 390 degrees Fahrenheit, the first heat source 210 is activated for about 35 seconds (e.g. the first predetermined length of time). After about 35 seconds the first heat source 210 is deactivated for about 10 seconds (e.g. the second predetermined length of time). The second heat source 211 is then activated for about 40 seconds (e.g. the third predetermined length of time) for providing heat above the items being baked. After about 40 seconds, the second heat source 211 is deactivated for about 15 seconds (e.g. the fourth predetermined length of time) before the cycling of the first and second heat sources 210, 211 is repeated. It should be understood that the temperature ranges and corresponding heat source on/off time periods described above are for exemplary purposes only and that in other examples the temperature ranges and heat source on/off time periods may be other suitable temperature ranges and time periods.

It should be understood that while the operative cycling of the first and second heat sources 210, 211 is divided into the two temperature ranges describe above, the oven can be operated at any suitable temperature for baking foods. For example, a user may select a desired baking temperature and/or baking time. Alternatively the user may select pre-programmed time temperature combinations for certain types of baked goods. If the user selected baking temperature is (or all the temperatures of a select pre-programmed time temperature combination are) below, for example, about 390 degrees the first and second heat sources will be cycled as described above for baking temperatures below about 390 degrees Fahrenheit. If the user selected baking temperature is (or all the temperatures of a select pre-programmed time temperature combination are) above, for example, about 390 degrees the first and second heat sources will be cycled as described above for baking temperatures above about 390 degrees Fahrenheit. If a pre-programmed time temperature combination is selected a combination of the operational cycles for the first and second heat sources may be used. For example, if the first timed temperature is about 425 degrees Fahrenheit the first and second heat sources will be cycled as described above for temperature above about 390 degrees for the predetermined time period. If the second timed temperature in the pre-programmed time temperature combination is about 250 degrees Fahrenheit the operational cycling of the first and second heat sources 210, 211 will be switched so that the first and second heat sources 210, 211 are cycled as described above for temperatures below about 390 degrees.

By cycling the first and second heat sources 210, 211, and leaving sufficient time off between the cycles, sufficient gas pressure to each heat source is assured as is complete combustion of the supplied gas, since the first and second heat sources are never on simultaneously. For example, the fuel pressure provided by the fuel source 290 may be limited such that both the first and second heat sources 210, 211 cannot be activated simultaneously. It is noted that in other alternate embodiments, an electric powered heat source, such as an electric resistive heater or radiant element may be disposed adjacent the top 200T of the gas oven cavity 200 and be used in lieu of or in addition to the gas element 211 in a manner substantially similar to that described above with respect to the cycling of the first and second heat sources 210, 211. It is also noted that while the above example illustrates an alternating cycling of the first and second heat sources 210, 211, it should be understood that the first and second heat sources 210, 211 do not have to be cycled alternately. For example, the fuel to the first and second heat sources 210, 211 may be modulated between the first and second heat sources 210, 211 through suitable valving so that sufficient gas pressure to each heat source is assured as is complete combustion of the supplied gas. The amount of fuel provided to each of the first and second heat sources 210, 211 may be adjusted as needed to provide a desired temperature towards the bottom and top of the oven cavity during the baking cycle so that sufficient browning of the food is achieved.

The control unit 170 may include any suitable components for effecting the cycling of the first and second heat sources 210, 211 as is described herein. In one embodiment, the control unit 170 may include a memory 171 for storing information and data related to the execution of the processes described herein, such as for example, the cycling rate control data for the burners. In one embodiment, the cycling rate control data can be specified by, for example, the manufacturer of the cooking appliance 100 (or any other suitable entity) during manufacture of the cooking appliance 100 or during service of the cooking appliance 100 in the field. The memory may include any other suitable memory, storage device or computer readable storage medium. The control unit 170 can also include one or more processors configured to access, for example, the memory 171 for obtaining the cycling rate control data and for controlling the cycling and an amount of heat produced by the first heat source and/or second heat source during baking in response to inputs to the control unit 170. The processor(s) and/or memory may include, or have embodied thereon, any suitable computer readable program code for executing the processes and control of the cooking appliance 100 as described herein.

Thus, while there have been shown and described and pointed out fundamental novel features of the invention as applied to the exemplary embodiments thereof, it will be understood that various omission and substitutions and changes in the form and details of devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps, which perform substantially the same way to achieve the same results, are with the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. 

1. A gas cooking appliance comprising: a gas oven cavity for baking an food item, the gas oven cavity including a top surface and a bottom surface; a first heat source disposed adjacent the bottom surface of the gas oven cavity; a second heat source disposed adjacent the top surface of the gas oven cavity; and a controller configured to cycle the first heat source and the second heat source for providing heat above and below the food item during baking.
 2. The gas cooking appliance of claim 1, wherein at least one of the first heat source and second heat source comprises a gas burner.
 3. The gas cooking appliance of claim 1, wherein the second heat source comprises at least one of a gas burner, or an electric heating element.
 4. The gas cooking appliance of claim 1, wherein the controller is configured to cycle the first heat source and the second heat source such that between activation of one of the first heat source and the second heat source, the first heat source and the second heat source are off for a predetermined period of time.
 5. The gas cooking appliance of claim 4, wherein the predetermined period of time is selected to allow for sufficient fuel pressure for activation of that one of the first heat source and second heat source that is to be activated.
 6. The gas cooking appliance of claim 4, wherein the predetermined period of time is selected to allow for substantially complete combustion of fuel by that one of the first heat source and second heat source that has been deactivated.
 7. A system for cycling a first heat source and a second heat source during a bake cycle of a gas cooking appliance, the gas cooking appliance having a gas oven cavity and the first heat source and the second heat source are disposed inside the gas oven cavity, the system comprising: a controller configured to cycle the first heat source and the second heat source for providing heat above and below a food item placed within the gas cooking appliance; and the gas oven cavity includes a top surface and a bottom surface, the first heat source being disposed adjacent the bottom surface and the second heat source being disposed adjacent the top surface.
 8. The system of claim 7, wherein the controller comprises a memory, the memory including selectable parameters for specifying the cycling of the first heat source and the second heat source.
 9. The system of claim 7, wherein at least one of the first heat source and the second heat source comprises a gas burner.
 10. The system of claim 7, wherein the second heat source comprises at least one of a gas burner, and an electric heating element.
 11. The system of claim 7, wherein the controller is configured to cycle the first heat source and the second heat source such that between activation of one of the first heat source and the second heat source, the first heat source and second heat source are off for a predetermined period of time.
 12. The system of claim 11, wherein the predetermined period of time is selected to allow sufficient fuel pressure for activation of that one of the first heat source and second heat source that is to be activated.
 13. The system of claim 11, wherein the predetermined period of time is selected to allow for substantially complete combustion of fuel by that one of the first heat source and second heat source that has been deactivated.
 14. A method for cycling a first heat source and second heat source of a gas cooking appliance during baking, where the gas cooking appliance includes a controller and a gas oven cavity having a top surface and a bottom surface, the first heat source being disposed adjacent the bottom surface and the second heat source being disposed adjacent the top surface, the method comprising: activating one of the first heat source and the second heat source with the controller; activating the other of the first heat source and the second heat source with the controller; and between activation of the one of the first heat source and the second heat source and activation of the other of the first heat source and the second heat source, deactivating both of the first heat source and the second heat source with the controller for a predetermined period of time, wherein at least one of the first heat source and the second heat source comprises a gas burner.
 15. The method of claim 14, wherein the second heat source comprises at least one of a gas burner or an electric heating element.
 16. The method of claim 14, wherein the predetermined period of time is selected to allow sufficient fuel pressure for activation of that one of the first heat source and the second heat source that is to be activated.
 17. The method of claim 14, wherein the predetermined period of time is selected to allow for substantially complete combustion of fuel by that one of the first heat source and the second heat source that has been deactivated. 